The fabrication yard has equipment and personnel necessary to received and store materials, to pre-fabricate, fabricate, erection, blasting and painting to perform pre-commissioning and load-out offshore Platforms, Decks, Jackets, Modules, Steel Structures and Process Equipment for energy related and Industrial plant project.
Two buildings with three levels each, with total area 3.800 m2 are available for fabrication yard main office and client representative office.
There are also offices located in various areas of the fabrication yard for fabrication, erection, assembly, maintenance, blasting, painting, warehouse and others.
There are several fabrication shops with total are + 12,500 SQM, complete with equipment to fabricate of pipe spools, assembly of pressure vessels, skid mounted process equipment, electrical and instrumentation.
The area of each Shop as follows:
1. Fabrication Shop 1 : 90 x 16 SQM 2. Fabrication Shop 2 : 90 x 30 SQM 3. Fabrication Shop 3 : 54 x 26 SQM 4. Fabrication Shop 5 : 140 x 30 SQM plus 84 x 17 SQM 5. Fabrication Shop 6 : 55 x 24 SQM 6. Portable Shops.
Equipment in this area as follows:
One of miscellaneous shops which area of 2400 SQM for cutting and profil
There are 2 (two) covered warehouse which has on overall surface in the total area 2,012 SQM. 1 (one) warehouse at inside of gate-2 and the other one is at yard-2. Both warehouses are available as customs bonded warehouse:
1. Warehouse-1 at inside of yard-1 = 20 x 41 SQM (1 bay)
2. Warehouse-2 at inside of yard-2 = 52 x 54 SQM (3 bays)
Material Storage Area
The Customs bonded steel material open storage is approx. 176,559 SQM and has able space for storage of both Client (s) and Contractors materials. The open storage area is split into 2 locations:
Open storage inside yard-1
Open storage inside yard-2
All workshops are equipped with various capacity of overhead traveling cranes.PTG has own traveling cranes to support the construction activities at open area, i.e.:
It is possible to rent from local crane Rental Company.
There are 2 (two) units working table with the following dimension:
1. Working table-1 at inside yard-1 = 20x48m 2. Working table-2 at inside yard-2 = 2@15x30m
In which generally to be used for assembly of deck section and pre-fabrication of beams and branches.
There are 2 (two) jetties which is used for load-out of structures and most of the offloading and loading of material. The jetty-1 has a bulkhead 106m (length) x 15m (width) and minimum water depth of (-) 7.5m from chart datum. The jetty-2 has a bulkhead 80m (length) x 15m (width) and minimum water depth of (-) 7m from chart datum.
The jetties were designed for distribution load for 500T/m for the 1st of 4m from jetty tip, 400T/m for the 2nd of 4m, 350T/m for the 3rd of 5m and 250T/m along the skid-way.
The minimum water depth at the load-out jetty is (-) 7 up to (-) 7.5m from chart datum and is at least this depth through natural channels leading to the open sea. There is no problem (obstructions, overhead clearance, and bends, channel widths or water depths) in bringing with the structures from the fabrication yard.
Load Out System
The skid-ways were designed for skidding load-out method with skid-way spacing 12.19m/20m at jetty-1 and 15.2m at jetty-2. The bulkhead were build at jetty tip to allow for loading/unloading activity with the capacity for bearing load up to 25 Ton/m2.
The skid-ways are 1.2m (width) x 1.5m (depth) embedded, spaced at 12.19m & 20.00m (skid-way jetty-1) and 15.35m (skid-way jetty-2) center to center. The length of skid-way jetty-1 is 300m and 153m for jetty-2 and both jetty facing to open sea. Along the skid-ways there are electrical outlets for 380 V rectifier-welding machines and compressed air outlets.
The structure/modules can be fabricated in the skid-way up to 100m length and for weighing the structure up to 15.000Te.
Beside skid-way system, the multi-wheel method and the lifting method also possible to use for load-out system at GUNANUSA Fabrication Yard.
Blasting & Painting Area
This area is mainly used for blasting and priming works, the final painting work is done wherever it is convenient. Equipment in this area consists of:
The area of blasting & painting as the follows :
Equipment in this area as follows:
In additional, there are 6 (six) Clemco Post available for use where required. Besides above area, there is one Thermal Spray Almunium (TSA) Coating area (1000 SQM) complete with equipment.
The welding school is available for training and examination of ability all the welder before working in project, so that the project could be finish with the best quality and on time schedule it is also a Welding facility for making PQR (Procedure Qualification Record) and WPS (Welding Procedure Specification).
Total supply capacity is 1,730 KVA from PLN Power source and main generator house supplying 2,100 KVA. Fabrication Yard power is distributed from the main powerhouse with 20,000 volt underground distribution system to the each power house.
This power distribution area:
There are 2 x 500 KVA, 1 x 550 KVA, 2 x 200 KVA and 1 x 150 KVA Emergency Generators, which available to supply power where, required.
The generators produce 380/220 Volt, 50 Hz, Power equipment located in this area consists of:
Yard Lighting System
The yard lighting consists of:
Repair and Maintenance Area
The area designated for repair and maintenance houses the machine shop, electrical shop, tire & body repair shop and offices. The open area consists of wash & lubrication racks equipment repair & overhaul facilities and diesel fuel & gasoline storage facilities.
In additional to the standard tools the Machines shop is equipment with:
The electrical shop has the usual electrical maintenance tools
PTG security is operated by a team of 30 security guards and one Chief Security and allows for a 24-hour shift operation covering 13 check stations.
The yard area some 176,559 SQM is protected from public access by a security brick wall 3 M high and constructed of steel pipes with plastic covered wire mesh. There are unfenced boundaries but these are secured by the sea front. Paint and Oxy-acetylene bottle are sparely housed in a secure fenced are within the yard.
A 24 hour watch is maintained at the main gates access to the yard is gained only after the security officer has obtained signed authorization from management for each and every request to enter.
Rest area and accommodation room of employees with a capacity of approximately 500 employees, equipped with locker space for 500 employees.
In addition, we have also mess area has several rooms which can house up to 120 single status personnel and provides cover for the amenities of kitchen, laundry, mess hall, video lounge, canteen client and recreation rooms.
Clinic and Ambulance
Clinic with the doctor, paramedic and ambulance are available at GUNANUSA Fabrication Yard for first aid of accident during fabrication and construction.